Structural Insulating Core Wall With A Reverse Lip Channel
The present invention relates to a structural insulating core wall consists of spacer blocks with a tongue space and a groove space interlocking the spacer blocks between vertical metal support channels and the horizontal bracing channels forming a horizontal tongue and trough within the spacer blocks connecting the spacer blocks, vertical support channels and horizontal bracing channels together. Various types of horizontal bracing channels, support channels, couplings, hole shapes within the support channels and orientation of the various elements and the shape of the spacer blocks changes affect how the structural insulating core wall is used including the type of material the spacer blocks made of.
This application is a continuation-in-part of two pending patents U.S. Ser. No. 12/231,875 filed Sep. 8, 2008 and U.S. Ser. No. 12/456,707 filed Jun. 6, 2009. In addition this application contains information on two provisional patent applications U.S. Ser. No. 61/628,044 filed on Oct. 24, 2011 and U.S. Ser. No. 61/629,442 filed Nov. 22, 2011.
BACKGROUND OF THE INVENTION(1) Field of the Invention
The present invention relates to an improved wall system where the structural insulating core uses various wall forming structures and spacer blocks interconnecting between each other. Another aspect is a new horizontal bracing channel and electrical chases incorporated into the wall forming structure.
(2) Background of the Invention
Exterior metal framing has always been difficult to insulate because of the configuration of the support channels like a C channel. The lip and flange of the C channel protrudes from the web making it difficult to insulate. When horizontal bracing channels are installed between support channels for additional strength, insulation became even more difficult to install as well as form a good insulated wall.
The metal framing was installed first, then a rigid insulation was installed on the exterior, mechanicals were then added and a fibre glass insulation was installed between the support channels. Later insulation was blown into the wall cavity that is between the support channels after the sheathing was installed on the exterior.
Closed cell rigid insulation has been increasing in popularity, however the solutions has been to mold the closed cell insulation into the support channels. In addition, closed cell rigid insulation has been cut into panels where several support channels slide into the rigid insulation panel from the top of the rigid insulation in order to install the support channels. The closed cell rigid insulation solutions are usually installed in a manufacturing plant rather that at the job site.
The creation of a smaller spacer blocks that has flexibility to be assembled into panels at a manufacturing plant or at the construction site as well as incorporating various types of horizontal bracing channels and electrical chases or troughs gives the spacer block additional flexibility. In addition, the size of the spacer block can vary depending on the type of closed cell rigid insulation is used like polystyrene, cellular light weight concrete or aerated autoclaved concrete.
The horizontal bracing channels within the wall forming structure is generally provided by installing bridging members which tie the support channels together. These bridging members may be attached on the outside of the flanges of the support channels or maybe internal bridging members installed through openings provided in the web of the support channels. None of the bridging members used today have a limited function and do not provide a solution for interacting with rigid insulation between support channels and the holes the internal bridging members pass through.
DESCRIPTION OF PRIOR ARTThere are many different aspects to the invention which involves many different subjects which are noted below.
Foam Block With Holes
In U.S. Pat. No. 5,842,276 by Ashner cuts a hole in a larger block so a conduit can be installed. The block remains as one piece and a tongue and groove connection is not incorporated in the assembly of the synthetic panel.
In U.S. Pat. No. 7,028,440 (filed Nov. 29, 2003) by Brisson uses foam blocks with vertical holes to form concrete columns and uses a horizontal recess at the top of the panels to form a beam pocket. The foam panels are made using a tongue and groove type connections between panels and the panels are glued together. Since the holes for the concrete are only support by foam, the size is limited as the concrete will deform as well as break the foam panels. Again the beam pocket is also fragile as there is not support to stop the wet concrete from deforming the beam.
Foam Panel
In U.S. Pat. No. 5,943,775 (filed Jan. 7, 1998) and U.S. Pat. No. 6,167,624 (filed Nov. 3, 1999) by Lanahan uses a polymeric foam panel with metal channels installed within the foam. The panels are interlocked together by a tongue and groove connection using the foam as the connector. An electrical conduit is horizontally installed within the panel for electrical distribution. The metal channels are embedded within the foam. Walpole in U.S. Pat. No. 7,395,999 embeds a metal channel in foam for support and uses a tongue & groove joint sealer between panels. In U.S. Pat. No. 5,722,198 (filed Oct. 7, 1994) and U.S. Pat. No. 6,044,603 (filed Fe. 27, 1998) by Bader discloses a panel & method to form a metal channel and foam panel where the flanges are embedded into the sides of the foam panels. In U.S. Pat. No. 5,279,088 (filed Jan. 17, 1992), U.S. Pat. No. 5,353,560 (filed Jun. 12, 1992) and U.S. Pat. No. 5,505,031 (filed May 4, 1994) by Heydon show a wall and panel structures using overlapping foam and metal channels in various configurations. Carlin in U.S. Pat. No. 5,822,940 uses support channels that slide vertically into the wall panel.
Horizontal Bracing Channels
Rice in U.S. Pat. No. 8,011,160 uses a bracket to connect the horizontal bracing channels to the vertical C channels. Poliquin in U.S. Pat. No. 6,199,336 uses a tab to hold the horizontal bracing channel to the vertical support channel. diGirolamo in U.S. Pat. No. 7,596,921, U.S. Pat. No. 7,836,657 & U.S. Pat. No. 6,701,689 shows various horizontal bracing channels, however the U channel facing downward with groove is shown in the pending patent used in conjunction with the spacer blocks. Dietrich Industries uses Brunt in U.S. Pat. No. 7,017,310, Elderson in U.S. Pat. No. 6,920,734 & U.S. Pat. No. 6,708,460, U.S. Pat. No. 7,168,219, U.S. Pat. No. 7,159,369 and Collins in U.S. Pat. No. 6,694,695 to disclose to show a V shaped horizontal bracing channel between the vertical support channels of a metal framing system. The V shaped horizontal bracing channel is always pointing upward and is not used in conjunction with a spacer block. The V shaped is used in the pending patent along with the spacer block and incorporating various hole configurations. Hughes in U.S. Pat. No. 6,164,928 forms a horizontal bracing channel that does not reflect the pending patent.
Channel Indentations
Rice in U.S. Pat. No. 7,849,640 uses an indentation in the support channel and has a base channel and a support channel connection, but does not reflect how the channel indentation is applied in the pending patent. In U.S. Pat. No. 7,836,657 by diGirolamo uses channel indentations to explain a horizontal bridging member, but does not relate the indentations to spacer blocks. Meyer in U.S. Pat. No. 5,157,883 uses an indentation in the metal channels to describe a clip.
Holes in Vertical Channels
Edmondson in U.S. Pat. No. 7,866,112 uses a punched hole with flanges to form the holes in the vertical channels of a metal framed wall. Bodnar in U.S. Pat. No. 4,793,113 show large holes with bent flaps does not reflect the pending patent.
SIP
Structural insulated panels known as SIP's are typically made using rigid insulation in the middle with plywood on both sides and wood blocking or metal connectors are installed in the middle connecting the two panels together.
Porter has developed many SIP patents using metal components including U.S. Pat. No. 5,497,589, U.S. Pat. No. 5,628,158, U.S. Pat. No. 5,842,314, U.S. Pat. No. 6,269,608, U.S. Pat. No. 6,308,491, and U.S. Pat. No. 6,408,594 as well as Babcock U.S. Pat. No. 6,256,960, Brown U.S. Pat. No. 6,564,521 and Kligler U.S. Pat. No. 6,584,742 of which Babcock shows a metal channel between two panels to interlock adjacent panels. In U.S. Pat. No. 5,638,651 uses metal channels at interior but does not have a thermal break on the metal channels. Porter shows 5 more patents using wood and one more U.S. Pat. No. 5,950,389 using splines to interlock panels.
Panel Construction
In U.S. Pat. No. 5,638,651 filed Jun. 21, 1996 by Ford uses an interlocking panel system where two U channels interlocks with an OSB board and the metal channel to form a building panel. In U.S. Pat. No. 6,701,684 filed Jun. 26,2002 by Stadler uses vertical back to back U metal channels in a foam panel and a cementous coating over the foam to form a wall. In U.S. Pat. No. 6,880,304 filed Sep. 9, 2003 by Budge, uses vertical slotted framed to support a foamed wall assembly.
SUMMARY OF THE INVENTIONThe present invention relates to an improved wall system where a structural insulating core wall uses various wall forming structures and spacer blocks interconnecting between each other. The various support channels, horizontal bracing channels, holes in the web of the support channels and base plates all alter the shape of the spacer blocks. The orientation of the holes, support channels, horizontal bracing channels also change the shape of the spacer blocks and the type of material used to form the spacer blocks. The spacer blocks have vertical and horizontal interlocking tongue and groove connections that connect between the wall forming structure and the spacer blocks. The spacer blocks can cover the flanges of the support channels or just protrude beyond the support channels to form a thermal break.
Another variation of the invention is when the spacer blocks are wider than the support channels, but do not overlap the flanges of the support channels. The inner and outer boards that are installed over the spacer blocks are not in contact with the support channels and a gap occurs creating a thermal break in the improved wall system.
Various types of electrical chases can be installed within the structural insulating core depending on the shape of the horizontal bracing channels. The horizontal bracing channel can be oriented so the U or V shape of the horizontal bracing channel is oriented upward or downward causing the trough within the spacer channel or the electric chase to be above or below the horizontal bracing channels and whether the horizontal bracing channel fits within the trough or is larger than the trough within the spacer blocks. When the horizontal bracing channel is larger than the hole in the web of the support channels, a notch is added to the lip of the horizontal bracing channels to secure the channels together. When two horizontal bracing channels are installed into the same hole of the support channel and one horizontal bracing channel is reversed, the reversed horizontal bracing channel becomes a cover over the other horizontal bracing channel.
Various types of holes in the web of the support channels will have an effect on the horizontal bracing channels by allowing additional notches to be installed within the horizontal bracing channels.
Brackets which are shorter than full height support channels can be used when constructing a wall forming structure. The brackets also have a hole into which the horizontal bracing channel can connect to allowing the spacer blocks to be secured together when load bearing materials can be used rather than closed cell insulation materials.
Another aspect of the invention is that exterior wall sheathing and interior rigid insulation in a wall are formed as one and together form an integrated material referred to a spacer block. The integrated wall sheathing speeds construction since usually two different construction trades installs the wall sheathing and the interior insulation and the spacer blocks provides a measurement say 16″ or 24″ on center for a faster wall installation.
Another aspect of the pending patents it the formation of a structural insulating panel (SIP) when the structural insulating core and the rigid board and rigid insulating are all glued together.
Different types of wall forming supports, horizontal bracing channels and the holes within the support channel are shown as a wall structure. Spacer blocks are used between the wall structure interlocking the spacer blocks together. The tongue space and groove space within the spacer blocks interlock the spacer blocks and support channels together.
The various holes shapes are shown in the support channels and the horizontal bracing channels, holes and trough locations within the spacer block can reversed to achieve different configurations. The spacer blocks interlock with overlapping flanges at the support channels.
Another structural insulating core wall is when the spacer block does not cover the support channels forming a gap between the spacer blocks for a better thermal break from the support channels.
A horizontal reverse lip channel with notches forms a new horizontal bracing channel and greater strength and versatility.
It is understood that the invention is not to be limited to the exact details of operation or structures shown and describing in the specification and drawings, since obvious modifications and equivalents will be readily apparent to those skilled in the art. The flexibility of the described invention is very versatile and can be used in many different types of building applications.
Claims
1. A structural insulating core wall of a building comprising of:
- spaced apart vertically oriented metal support channels with holes, horizontal bracing channels that pass through the holes, spacer blocks positioned between and at least spanning the distance between the channels, consisting of:
- spaced apart vertically oriented metal support channels that have two flanges and a web with a hole in the web;
- a hole in the webs so the horizontal bracing channel can be lodged in the holes of the vertically oriented metal support channels securing itself to the sides of the holes;
- a block depth dimension greater than the depth of the support channels, a groove and a transverse mating tongue fully extending along a transverse length of facing, opposed side block surfaces, the groove and tongue surfaces contacting the web and channel flanges without overlapping the flanges, a base plate groove running perpendicular to the tongue and groove, the base plate groove in a bottom block face and positioned from a front or back surface a dimension equal to a foam thickness from the front or the back of the block to the channel flange and,
- a base plate having a flange inserted in a base angle groove of the blocks, the base plate flanges secured to the channel flanges, and, another base plate flange, perpendicular to the first, secured to a building floor adjacent the structural insulating core wall.
2. The structural insulating core wall of claim 1 wherein bracing is fastened over the spacer block to the support channel flanges.
3. The structural insulating core wall of claim 1 wherein the support channels and spacer blocks are glued together to form the wall.
4. The structural insulating core wall of claim 1 including a trough with a horizontal bracing channel aligned with the holes in the support channel, and in the middle of the block, the trough parallel to the base plate groove, and aligned with holes in the channels, and a horizontal tongue fitting into the trough of another spacer block.
5. The structural insulating core wall of claim 4 wherein the horizontal tongue of the spacer block fits between the flanges of the horizontal bracing channel.
6. The structural insulating core wall of claim 1 including inner and outer rigid boards adhered to both sides of the structural insulating core.
7. The structural insulating core wall of claim 6 wherein the support channel at the flanges forms a gap separating the spacer blocks and between the inner or outer rigid boards.
8. The structural insulating core wall of claim 1 wherein the spaced apart vertically oriented elongated metal support channels have a web with flanges perpendicular to the web with lips parallel and oriented away from the web.
9. The structural insulating core wall of claim 1 where the spaced apart vertically oriented metal support channels have an indentation in the web so the vertical projection of the spacer blocks can fit into and around.
10. The structural insulating core wall of claim 1 wherein the hole of the vertically oriented support channel is sloped corresponding to the slope of the horizontal bracing channel.
11. The structural insulating core wall of claim 10 wherein the sloped hole in the support channel has a blunt end at the vortex allowing the flanges of the horizontal bracing channel to engage with the sloped sides of the hole.
12. The structural insulating core wall of claim 7 wherein rigid board fillers separate the inner and outer rigid boards from the support channels.
13. The structural insulating core wall of claim 1 wherein a coupling is a horizontal bracing channel that is short in length that passes through the hole in the support channels connecting the trough or horizontal tongue of the spacer block.
14. The structural insulating core wall of claim 1 wherein U shaped horizontal bracing channels are connected end to end by a coupling consisting of a web and two flanges and where the flanges and the web fits between the web and flanges of the U shaped horizontal bracing channels align with each other forming a continuous horizontal bracing channel.
15. The structural insulating core wall of claim 14 wherein the horizontal reverse lip bracing channel is a coupling consisting of a web and two flanges where the flanges and the web fits between the web and flanges of the horizontal reverse lip bracing channels and the notch in the lip of the coupling fit into the hole of support channel.
16. The structural insulating core wall of claim 15 wherein the coupling connects two perpendicular structural insulating walls at the corner with notches and flexible tabs at both ends fitting between the holes of the support channels of each structural insulating walls.
17. The structural insulating core wall of claim 1 wherein the spacer block depth dimension being greater than the depth of the support channels comprising of two smaller depth spacer blocks of different physical properties being supported by the tongue and groove shapes at the support channels.
18. The structural insulating core wall of claim 16 wherein the spacer block overlaps the flange of the support channel on one side of the support channel and extends past the flange on the opposite side.
19. The structural insulating core wall of claim 1 wherein the shape of the hole in the support channels, profile and orientation of the horizontal bracing channel determines wherein the horizontal tongue fits into the trough or the horizontal bracing channel profile interlocking each together within the spacer block.
20. The structural insulating core wall of claim 18 wherein the profile of the electric chase as described in claim 70 has a horizontal trough in the spacer blocks that the top and bottom of the spacer blocks for the electric chase to fit into.
21. The structural insulating core wall of claim 1 wherein the spaced apart oriented metal support channels are oriented horizontally and positioned between the spacer blocks as described in claim 33.
22. A spacer block between vertically oriented metal support channels positioned between and at least spanning the distance between the channels and between horizontally spaced apart members connected to the vertically oriented metal support channels and positioned between and at least spanning the distance between the horizontally spaced members comprising of:
- a horizontal block dimension positioned between and at least spanning the distance between the vertically oriented metal support channels; wider than the width of the web of the support channels; the width does not overlap the flanges of the vertical channels support; and interlocking between causing a tongue shape and a groove shape between the vertical support channels
- a vertical block dimension positioned between and at least spanning the distance between the horizontally spaced apart members; a width equal to the width of the horizontal block dimension;
- a horizontal trough wherein a horizontally spaced apart member fits into and aligns with the holes of the vertical support channels;
- a horizontal tongue that fits into the horizontal trough of an adjacent spacer block.
23. The spacer block according to claim 22 wherein the horizontal tongue is rectilinear and fits between the flanges and against the web of a horizontally spaced member.
24. The spacer block according to claim 22 wherein two spacer blocks are connected by the horizontal tongue of one spacer block fitting into the horizontal channel and the other spacer block and the adjacent spacer block with is horizontal trough fits over the horizontally spaced apart member and aligns with the holes of the support channels.
25. The spacer block according to claim 22 wherein the horizontal tongue is rectilinear and has grooves on both sides of the horizontal tongue where the flanges of the horizontal bracing channel flanges fit into and against the web of a horizontally spaced member.
26. The spacer block according to claim 22 wherein the horizontal tongue is V shaped and fits into the flanges of the horizontally spaced member.
27. The spacer block according to claim 26 wherein the V shaped horizontal tongue or horizontal trough have a rectilinear extension added for the V shaped horizontal bracing member.
28. The spacer block according to claim 22 wherein the horizontal trough is rectilinear in shape.
29. The spacer block according to claim 22 wherein the horizontal trough is V shaped.
30. The spacer block according to claim 29 wherein the horizontal trough has a combination of rectilinear sides and angular sides for a horizontal V shaped horizontal bracing member to fit into.
31. The spacer block according to claim 28 wherein the width of the horizontal trough is the width of a U shaped horizontal bracing channel.
32. The spacer block according to claim 22 wherein the horizontal trough has a combination of rectilinear sides and a round trough for a round horizontal bracing member to fit into.
33. The spacer block according to claim 22 wherein the two reverse lip horizontal bracing channels are inverted to each other requiring a horizontal trough on the top and bottom of the spacer block corresponds to the width of the webs of the elongated channels for the elongated channels to fit into.
34. The spacer block according to claim 22 wherein the tongue shape between the vertical support channels has a vertical indentation in the support channels and the groove shape within the spacer blocks have a vertical projection that fits into the indentation of the support channel.
35. The spacer block according to claim 22 wherein the horizontal block dimension positioned between and at least spanning the distance between the vertically oriented metal support channels; wider than the width of the web of the support channels has one projection that extends over the flanges of the vertical support channels interlocking between causing a tongue shape and groove shape between the vertical support channels and the opposite projection that extends past the flanges and does not overlap the flanges of the vertical support channels.
36. The spacer block according to claim 22 wherein the horizontal and vertical block dimension positioned between and at least spanning the distance between the vertically oriented metal support channels; the width covering the holes in the vertical support channels on one side and extending past the flange on the other side and engaging a horizontal trough wherein a horizontally spaced apart member fits into and aligns with the holes of the vertical support channels.
37. The spacer block according to claim 22 wherein the vertical block dimension positioned between and at least spanning the distance between the horizontally spaced apart members is smaller having a vertical hole installed through the horizontal trough to another horizontally spaced apart member.
38. A support channel/horizontal bracing channel member comprising:
- an elongate member having a U shaped lateral cross-section having a web and two flanges and two lips jointed at the flanges and aligned with the web that defines a longitudinal axis; and
- at least two pair of spaced apart notches in at least one of said longitudinally extending lips for receiving and engaging a hole in a web of a support channel, each notch extending inwardly to the U shaped cross-section that is perpendicular to the longitudinal axis of the elongate member.
39. The horizontal bracing channel member of claim 38, wherein the notches extend inwardly in the same direction.
40. The horizontal bracing channel member of claim 38, wherein the notches extend inwardly at an angle.
41. The horizontal bracing channel member of claim 38 wherein the horizontal bracing channel is a coupling consisting of a web and two flanges and long enough to where the flanges and the web fits between the web and flanges of the horizontal U bracing channels located on either side of the coupling and the notch in the lip of the coupling fit into the hole in the web of the support channel.
42. The horizontal bracing channel member of claim 38, wherein the horizontal bracing channel is a clip consisting of a web and two flanges with notches at the lips and where a continuous horizontal U channel fit into the flanges of the clip and the clip secures the continuous horizontal U channel to the hole in the web of the support channel.
43. A support channel/horizontal bracing channel member and a hole comprising;
- an elongated member having a V shaped lateral cross-section having each side define a longitudinal axis; and
- a hole where the edges in a hole in the web of a support channel align with the V shaped horizontal bracing channel when the V shape is pointing downward.
44. A support channel/horizontal bracing channel member and hole according to claim 43 wherein comprising:
- an elongated member having a V shaped lateral cross-section having each side define a longitudinal axis; and
- at least one notch for receiving and engaging a hole in a web of a support channel;
- a hole where the edges are angular conforming to the V shaped horizontal bracing channel with a horizontal edge at the vortex of the hole engaging the vortex of the horizontal bracing channel.
45. The support channel/horizontal bracing channel member and hole according to claim 43 wherein the sides of the horizontal bracing channel has grooves at both sides of the V shaped later cross-section engaging both sides of the hole in the support channel.
46. A support channel/horizontal bracing channel member comprising:
- an elongate member having a round hollow lateral cross-section that defines a longitudinal axis; and
- at least a continuous raised groove that spirals around the round hollow lateral cross-section a hole in a web of a support channel, each groove extending outwardly so the edges of the raised groove will engage the cross-section of the opening of the support channel; and
- an opening that conforms to the diameter of the horizontal bracing channel.
47. A metal framed wall comprising:
- of support channels each having at least two flanges interconnected by a web, the web of the support channel having an hole, and the support channels being arranged in a row with the holes in the webs thereof aligned with one another; and
- at least one horizontal bracing channel as set forth in claim 38 extending through the openings of the support channels, the support channels longitudinally spaced apart with notches engaging the web of the studs.
48. The metal framed wall of claim 38 wherein at least one horizontal bracing channel includes a second horizontal bracing channel set in reverse so the lips of the second horizontal bracing channel are adjacent to the first horizontal bracing channel to each other as set forth in claim 37 so the flanges and web of the second horizontal bracing channel extend above the first horizontal bracing channel forming an enlarged enclosure extending through the openings of the support channels forming a passageway for electric wiring.
49. The metal framed wall of claim 46 wherein at least one punched hole is installed in a horizontal bracing channel for means of attaching electric conduit to the horizontal bracing channel with the punched hole.
Type: Application
Filed: Feb 16, 2012
Publication Date: Jun 14, 2012
Inventor: Dennis LeBlang
Application Number: 13/398,243
International Classification: E04C 2/52 (20060101); E04B 2/32 (20060101); E04B 2/30 (20060101);